A forming device and method for forming a pack into a finished package, a folding unit for forming sealed packages of pourable food products, and a package

ABSTRACT

The invention relates to a forming device (42) for feeding along a forming path (B) a pack (3) which has at least one portion (6) to be folded into a finished package (2). The forming device (42) comprises a first surface (46a) and a second surface (46b) opposite to each other and adapted, in use, to cooperate respectively with a front wall (15) and a rear wall (10) opposite to each other of the pack (3) to be folded. The first surface (46a) comprises an at least partially concave forming section (8) adapted, in use, to cooperate with a top portion of the front wall (15) of the pack (3), such that an inward deformation of the top portion of the front wall (15) is prevented during forming of the pack (3). The invention also relates to a folding unit (1) for forming sealed packages (2) of pourable food products, to a method for forming a pack (3) which has at least one portion (6) to be folded into a finished package, and to a package (2).

TECHNICAL FIELD

The invention relates to a forming device and method for forming a packinto a finished package. The invention also relates to a folding unitfor forming sealed packages of pourable food products, and to a package.

BACKGROUND ART

As is known, many liquid or pourable food products, such as fruit juice,UHT (ultra-high-temperature treated) milk, wine, tomato sauce, etc., aresold in packages made of sterilized packaging material.

A typical example is the parallelepiped-shaped package for liquid orpourable food products known as Tetra Brik Aseptic (registeredtrademark), which is made by folding and sealing laminated strippackaging material.

The packaging material has a multilayer structure comprising a baselayer, e.g. of paper, covered on both sides with layers of heat-sealplastic material, e.g. polyethylene. In the case of aseptic packages forlong-storage products, such as UHT milk, the packaging material alsocomprises a layer of oxygen-barrier material, e.g. an aluminum foil,which is superimposed on a layer of heat-seal plastic material, and isin turn covered with another layer of heat-seal plastic material formingthe inner face of the package eventually contacting the food product.

Packages of this sort are normally produced on fully automatic packagingmachines, on which a continuous tube is formed from the web-fedpackaging material. The web of packaging material is sterilized on thepackaging machine, e.g. by applying a chemical sterilizing agent, suchas a hydrogen peroxide solution, which, once sterilization is completed,is removed from the surfaces of the packaging material, e.g. evaporatedby heating. The web so sterilized is then maintained in a closed,sterile environment, and is folded and sealed longitudinally to form atube, which is fed vertically.

In order to complete the forming operations, the tube is filled with thesterilized or sterile-processed food product, and is sealed andsubsequently cut along equally spaced cross sections.

More precisely, the tube is sealed longitudinally and transversally toits own axis.

Pillow packs are so obtained, which have a longitudinal seal, a toptransversal seal and a bottom transversal seal.

More specifically, the pillow packs comprise a parallelepiped-shapedmain portion, a top end portion and a bottom end portion. The top endportion and the bottom end portion taper from the main portion towardsthe top transversal seal and the bottom transversal seal, respectively.Each one of the top end portion and the bottom end portion hassubstantially triangular flaps projecting from opposite sides of themain portion and a rectangular tab projecting from a relative sealingline.

Packaging machines of the above type are known, on which the pillowpacks are turned into folded packages by automatic folding units.

Folding units are known, for example from the International ApplicationNo. WO2008122623 in the name of the same Applicant, which substantiallycomprise a rotary conveyor that receives pillow packs to be folded at aninlet station, conveys the pillow packs to be folded along an arc-shapedfolding path, and outputs folded packages at an output station. Thefolding units comprises a first folding unit which interacts withportions of the packs travelling along the folding path to perform afolding operation onto the packs, a heating device for heating the flapsof the packs travelling along the folding path, and a second foldingdevice for pressing the flaps of each pack travelling along the formingpath onto respective walls, as flaps cool.

In greater detail, the rotary conveyor comprises a plurality ofangular-spaced forming devices, which grip the packs at the inletstation, and feeds the packs along the forming path to the outputstation.

Each forming device comprises two flat surfaces which face each otherand cooperate, in use, respectively with a front wall and a rear wall ofthe main portion of the relative pack to be folded.

One problem that frequently occurs in known filling machine relates tothe final forming and folding of the pack into a package. For variousreasons, the top portion of the front wall of the package tends to bendinwardly, i.e. towards the inside of the package, and therefore tocreate a concave surface in the front wall of the finished package. Suchan undesired shape is likely to complicate post-application ofcomponents, such as an opening device, to the top portion of the frontwall.

SUMMARY OF THE INVENTION

It is an object of the present invention to mitigate, alleviate oreliminate one or more of the above-identified deficiencies in the artand disadvantages singly or in any combination and solve at least theabove mentioned problem.

According to a first aspect of the invention, these and other objectsare achieved in full, or at least in part, by a forming device forfeeding along a forming path a pack which has at least one portion to befolded into a finished package. The forming device comprises a firstsurface and a second surface opposite to each other and adapted, in use,to cooperate respectively with a front wall and a rear wall opposite toeach other of the pack to be folded. The first surface comprises an atleast partially concave forming section adapted, in use, to cooperatewith a top portion of the front wall of said pack, such that an inwarddeformation of the top portion of the front wall is prevented duringforming of the pack.

In other words, the forming section is configured to allow the topportion of the front wall to expand outwardly into the forming sectionduring forming of the pack without permanently deforming the pack. Thiswill result in a planar final configuration of the top portion of thefront wall. The top wall of the pack and a top portion of the front wallof the pack may thus be controlled to form a desired angle between eachother to facilitate post-application of components to these surfaces.The post-application normally consist of attaching an opening devicehaving a frame extending on two inclined planes to the package. Now, theopening device can be properly applied to the package since the anglebetween the above-mentioned planes will match the angle between the topwall and the front wall, particularly the top portion of the front wall,of the package. This way, the potential problem of leakage after firstopening of the opening device will be eliminated.

By giving the forming section a suitable shape, depending on thecircumstances, the final shape of the top portion of the front wall ofthe package can be controlled to match any potential post-applicationcomponents and filling configurations. In order to be able to adapt theforming section to different types of packages and post-applicationcomponents, the first surface may comprise a replaceable elementincorporating the forming section.

Furthermore, the extent of the concave shape of the forming section maybe varied by replacing one replaceable element with another. By changingthe extent of the concave shape of the forming section, the anglebetween the top wall and the front wall of the package may becontrolled. An increased extent of the concave shape will result in alarger angle between the top wall and front wall of the package, and theother way around.

In one embodiment, the replaceable element incorporating the formingsection may be replaced with a replaceable element having a planarsurface. In this case, the forming section will accordingly be planar,which is a suitable solution for some packages.

The forming device may further comprise a first body incorporating thefirst surface and a second body incorporating the second surface,wherein the first body and the second body, respectively, has a firstend zone and a second end zone opposite to the first end zone. In onepreferred embodiment of the invention, the first end zone may beconnected to a driving element and incorporate the forming section.

According to a second aspect of the invention, the objects are achievedin full, or at least in part, by a folding unit for forming sealedpackages of pourable food products. The folding unit comprises at leastone forming device as described above, and at least one folding deviceinteracting, in use, with the pack along the forming path and adapted tofold the at least one portion.

The folding unit may further comprise a heating device for heating, inuse, unfolded flaps of said pack. The folding device is arrangeddownstream from the heating device along the path and comprises pressuredevices, for example a pair of pressure devices. The pressure devicesare movable between an operative position in which pressing surfacespress the flaps of the pack onto relative walls of the pack to befolded, and a rest position in which the relative pressing surfaces aredetached from the pack.

According to a third aspect of the invention, the objects are achievedin full, or at least in part, by a package for containing a food productformed by means of a forming device as described above and/or folded bymeans of a folding unit as described above.

The top portion of the front wall of the package may be adapted toreceive an opening device.

According to a fourth aspect of the invention, the objects are achievedin full, or at least in part, by a method for forming a pack which hasat least one portion to be folded into a finished package. The methodcomprises the step of constraining the pack between a first surface anda second surface of a forming device arranged opposite to each other andadapted, in use, to cooperate respectively with a front wall and a rearwall of the pack to be folded. The first surface comprises an at leastpartially concave forming section. The method further comprises the stepof forming the pack by allowing a top portion of the front wall of thepack to expand outwardly into the forming section without permanentlydeforming the pack, and the step of folding the at least one portion ofthe pack into the finished package.

The top portion of the front wall of the pack, after the step offorming, is substantially planar.

The top portion of the front wall of the package may be adapted toreceive an opening device.

Generally, all terms used in the claims are to be interpreted accordingto their ordinary meaning in the technical field, unless explicitlydefined otherwise herein. All references to “a/an/the [element, device,component, means, step, etc.]” are to be interpreted openly as referringto at least one instance of the element, device, component, means, step,etc., unless explicitly stated otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

The above objects, as well as additional objects, features andadvantages of the present invention, will be more fully appreciated byreference to the following illustrative and non-limiting detaileddescription of preferred embodiments of the present invention, whentaken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a forming device for feeding a packalong a forming path to form a finished package according to a firstaspect of one exemplary embodiment of the invention.

FIG. 2 is a side view of the forming device of FIG. 1 when holding andforming a pack into a package.

FIG. 3 is a side view of a folding unit for forming sealed packages ofpourable food products according to a second aspect of one exemplaryembodiment of the invention.

FIG. 4 is a perspective view of a finished package according to a thirdaspect of one exemplary embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

FIGS. 1 and 2 illustrate a forming device 42 for feeding along a formingpath B (FIG. 3) a pack which has at least one portion 6, to be foldedinto a finished package 2. The forming device 42 comprises a firstsurface 46 a and a second surface 46 b opposite to each other and isadapted, in use, to cooperate respectively with a front wall 15 and arear wall 10 opposite to each other of said pack 3 to be folded. Thefirst surface 46 a comprises an at least partially concave formingsection 8 adapted, in use, to cooperate with a top portion of the frontwall 15 of the pack 3, such that an inward deformation of the topportion of the front wall 15 is prevented during forming of the pack 3.

The concave shape of the forming section 8 will allow the top portion ofthe front wall 15 to expand outwardly into the forming section 8 duringforming of the pack 3 without permanently deforming the pack 3. Thiswill result in a planar final configuration of the top portion of thefront wall 15. By controlling the shape and size of the forming section8, the top wall 17 of the pack 3 and the top portion of the front wall15 of the pack 3 may be controlled to form a desired angle to facilitatepost-application of components to these surfaces.

The forming device 42 has a driving element 20 that moves the formingdevice 42 in the forming path B. The pack 3 is formed into acorresponding package 2 while being advanced along the forming path B.In more detail, the forming device 42 has a first body 44 aincorporating the first surface 46 a and a second body 44 bincorporating the second surface 46 b. The forming section 8 of thefirst surface 46 a is arranged adjacent to the portion of the first body44 a that is connected to the drive element 20 of the forming device 42.

The first surface 46 a further comprises a replaceable element 9 whichincorporates the forming section 8. This way, the forming section 8 canbe given any suitable shape depending on the package 2 to be folded andfinalized. That is, the final shape of the top portion of the front wall15 of the pack 3 can be controlled to match any potentialpost-application components and filling configurations. In the presentembodiment, the replaceable element 9 has been chosen to give theforming section 8 a concave shape while the shape of the second surface46 b is planar. The concave shape will allow the top portion of thefront wall 15 of the pack 3 to expand outwardly into the forming section8 during forming of the same.

The forming device 42 also comprises a first member 45 a and a secondmember 45 b. The first member 45 a and the second member 45 b comprise,respectively, the first surface 46 a and the second surface 46 b whichface each other.

The first surface 46 a and the second surface 46 b cooperate,respectively, with the front wall 15 and the rear walls 10 of relativepack 3, so as to hold pack 3 along the forming path B.

Specifically, the first surface 46 a cooperates with the front wall 15of pack 3 intended to form the front wall 15 of the folded package 2 andthe surface 46 b cooperates with the rear wall 10 of pack 3 intended toform the rear wall 10 of the folded package 2.

In detail, the first surface 46 a is bounded by a rectilinear radialouter edge 50 and a rectilinear radial inner edge 51 which are oppositeto each other, and by a pair of edges 52 (only one of which shown inFIG. 2) which are opposite to each other and extend between the radialouter edge 50 end the radial inner edge 51.

The second surface 46 b is, in the embodiment shown, planar.

In the embodiment shown, the replaceable element 9 is distinct from thefirst member 45 a and releasably connectable to the first member 45 a.In this way, a replaceable element 9 provided with a forming section 8having a certain shape may be replaced with another replaceable elementprovided with a forming section having a different shape.

In another embodiment, not shown, the forming section is obtaineddirectly in the first member 45 a.

Each forming device 42 further comprises a slanted element 48 projectingfrom the radial inner edge 51 of the first surface 46 a of the member 45a towards the second surface 46 b and extending transversally to thesecond surface 46 b.

Each element 48 comprises a surface 49 extending from the first surface46 a towards the second surface 46 b. The surface 49 cooperates witheach pack 3 which is moved along the forming path B by the respectiveforming device 42.

FIG. 3 illustrates a folding unit 1 for forming sealed packages 2 ofpourable food products. The folding unit 1 comprises a rotary conveyor40 rotating around an axis C. The rotary conveyor 40 supports at leastone forming device 42 as described above. In the embodiment shown, therotary conveyor 40 supports a plurality of forming devices 42. Thefolding unit 1 further comprises at least one folding device 55, 65interacting, in use, with the pack 3 along the forming path B and beingadapted to fold the at least one portion 6.

A pressure device 66 of the folding device 65 is movable back and forthalong an axis G radial to axis C between a work position, in which itpresses the flaps of each pack 3 onto the walls of the pack 3, and arest position, in which it is detached from the flaps.

Pressure elements 67 are movable back and forth between a work position,in which relative surfaces press respective flaps of each pack 3 ontorespective walls, and a rest position, in which they are detached fromthe flaps to permit travelling of pack 3 along path B.

The movement of the pressure elements 67 is synchronized in a not shownmanner with the movement of the pressure device 66. When the pressuredevice 66 and the pressure elements 67 are in respective work positions,each pressure element 67 extends between the first surfaces 46 a and thesecond surface 46 b of the forming device 42 which is arranged at astation B5.

More specifically, the forming path B extends from a loading station B₁,where the conveyor 40 receives each pack 3 from an input conveyor 80, toan unloading station B₂, where the conveyor 40 unloads a relativepackage 2 onto an output conveyor.

From the loading station B₁ to the unloading station B₂, the formingpath B also comprises a first portion, along which rails interact witheach pack 3 to convert the pack 3 from a pillow configuration to aconfiguration in which the portions 6 are pressed towards each other tofold walls of portions 6, and to fold tabs onto respective walls, astation B₃ where an interacting surface interacts with each pack 3 tofold the flaps about fold lines, and a second portion, along which railsinteract with each pack 3.

From the second portion to the unloading station B₂, the forming path Balso comprises a station B₄ where a heating device 60 heats the flaps ofeach pack 3, preparatory to heat sealing them onto respective walls, athird portion, along which rails fold the flaps of each pack 3, thestation B₅ where the pressure device 66 and the pressure elements 67 ofthe folding device 65 fold the flaps of each pack 3 onto relative walls,and a fourth portion terminating at the ounloading station B₂, and alongwhich rails keep the flaps pressed onto the walls to prevent accidentaldetachment of the flaps as they cool.

FIG. 4 illustrates a finished package 2 according to one exemplaryembodiment of the invention. The package 2 has been provided with anopening device 14 after the final forming and folding of the same. Inthis case, the post-application consists of attaching the opening device14 to the top wall 17 and the front wall 15 of the package 2. Theopening device 14 has a frame extending along two inclined planes of thepackage 2, in particular a first portion 18 attached to the top wall 17of the package 2 and a second portion 19 attached to the front wall 15of the package 2. Here, the opening device 14 has been able to beproperly attached to the package 2 since the angle between the twoinclined planes, i.e. the angle between the first portion 18 and thesecond portion 19 matches the angle between the top wall 17 and the topportion of the front wall 15 of the package 2. This way, the potentialproblem of leakage will be eliminated.

It is understood that other variations in the present invention arecontemplated and in some instances, some features of the invention canbe employed without a corresponding use of other features. Accordingly,it is appropriate that the appended claims be construed broadly in amanner consistent with the scope of the invention.

For instance, the at least partially concave forming section may be anat least partially curved forming section.

The present invention can be used in connection with any suitable typeof filling machine and is not limited to the type of forming device 42or folding unit 1 described above. One example is a filling machinehaving a final folding unit constituted by a continuous chain device.This type of final folding unit comprises an articulated chain loopedabout and meshing with gears, and supporting a number of plates, forexample flat rectangular plates, each of which projects from the chainand cooperates with and pushes a pack 3 to feed it along a path. Here,the concave forming section 8 could be provided in connection with theplates in order to prevent an inward deformation of the top portion ofthe front wall during forming of the pack 3 into a finished package 2.

1-15. (canceled)
 16. A forming device for feeding along a forming path apack which has at least one portion to be folded into a finishedpackage, the forming device comprising: a first surface and a secondsurface opposite to each other and configured to interact respectivelywith a front wall of the pack to be folded and an opposing rear wall ofthe pack to be folded; wherein the first surface comprises: an at leastpartially concave forming section configured to interact with a topportion of the front wall of the pack and prevent an inward deformationof the top portion of the front wall during forming of the pack, whereinthe at least partially concave forming section is further configured toallow the top portion of the front wall to expand outwardly into the atleast partially concave forming section during forming of the packwithout permanently deforming the pack.
 17. The forming device accordingto claim 16, and further comprising a first body incorporating the firstsurface and a second body incorporating the second surface.
 18. Theforming device according to claim 17, wherein each of the first body andthe second body has a first end zone and a second end zone opposite tothe first end zone.
 19. The forming device according to claim 18,wherein the first end zone of the first body is connected to a drivingelement for driving the forming device along a forming path andincorporates the at least partially concave forming section.
 20. Theforming device according to claim 16, wherein the first surfacecomprises a replaceable element incorporating the at least partiallyconcave forming section.
 21. The forming device according to claim 20,wherein the replaceable element incorporating the at least partiallyconcave forming section may be replaced with another replaceable elementincorporating another forming section having an extent of the concaveshape different from the shape of the at least partially concave formingsection.
 22. A folding unit for forming sealed packages of pourable foodproducts, comprising at least one forming device according to claim 16,the folding unit comprising: at least one folding device interactingwith the pack along the forming path and adapted to fold the at leastone portion.
 23. The folding unit according to claim 22, and furthercomprising: a heating device for heating unfolded flaps of the pack,wherein the at least one folding device is arranged downstream from theheating device along the forming path.
 24. A method for forming a packwhich has at least one portion to be folded into a finished package, themethod comprising: forming the pack by allowing a top portion of a frontwall of the pack to expand outwardly into an at least partially concaveforming section without permanently deforming the pack; constraining thepack between a first surface and a second surface of a forming devicearranged opposite to each other and configured to interact respectivelywith the front wall and a rear wall of the pack to be folded, the firstsurface comprising the at least partially concave forming section;folding the at least one portion of the pack to form the finishedpackage.
 25. The method according to claim 24, wherein after forming thepack, the top portion of the front wall of the pack is substantiallyplanar.
 26. The method according to claim 24, wherein the top portion ofthe front wall of the package is configured to receive an openingdevice.